I have a sheet of .05" aluminum and I want to cut it up to makes things. What tools do i use to make a clean cut? I've cut this stuff before with some grinding type cutter but it left rough edges. On that particular piece, the edges were welded so it didn't matter. I'll need a smooth cut this time. Anyone got any ideas?

 

Try an air saw, or band saw.....has fine teeth that make a smoother cut.

 

electric/air powered shears work good for curves.. for perfect straight edges, a shear/brake works the best.

 

Try a nibbler. Thats what I've always used.

 

try as jig saw with some fine fine fine toothed blades. The electric nibblers work to.